Package Assembly with Tear Away Film and Manufacturing System

ABSTRACT

A package assembly includes a number of containers, a heat-shrink wrapping disposed around the containers and tear strip; the tear strip aids in opening the heat-shrink wrapping. The tear strip can be defined by perforations disposed through the heat-shrink wrapping and arranged in pathways. The perforations are cut in the heat-shrink wrapping with a packaging apparatus having a cutting member. The cutting member is used in combination with a die to leave a chad attached to heat-shrink wrapping. Thereafter, the heat-shrink wrapping is shrunk with a heating source in order to bundle containers together within the package assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of and priority to U.S. ProvisionalApplication No. 61/765,232, filed Feb. 15, 2013.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

In order to bundle containers together for shipment and storage, thecontainers are oftentimes bundled together in various ways. One way inwhich containers are bundled together is via the use of a heat-shrinkwrapping, which is subsequently heated. In this way, the containers arecontainers are held in a stable configuration.

The heat-shrink wrapping has certain disadvantages, however. One suchdisadvantage is that the heat-shrink wrapping can be difficult to removeonce transit of the containers is complete. Removal of the heat-shrinkwrapping can require tugging and tearing of the heat-shrink wrapping, orcutting it with a knife, scissors, or other sharp utensil. For theend-user of the product, this can be an onerous task. Further, with therise of safety concerns, some outlet stores have adopted “no-knife”policies. In these stores, the clerks, stockroom workers, and flooremployees are not allowed to carry cutting devices, making removal ofthe heat-shrink wrapping even more cumbersome.

An additional drawback of heat-shrink wrapping is that it has a tendencyto prevent cooling of the contents within the heat-shrink wrapping. Inparticular, heat from the packaging assembly can become trapped withinthe heat-shrink wrapping which, in some cases, can negatively impact thecontents within the containers.

In light of the drawbacks associated with traditional heat-shrinkwrapping and packaging methods and apparatuses, there is a need for apackage assembly, method, and apparatus that reduces or eliminates theneed for usage of specialty tools (e.g., knives, scissors, box cutters),facilitates cooling of the contents within the heat-shrink wrapping, andincreases the rate of packaging.

Without limiting the scope of the invention a brief summary of some ofthe claimed embodiments of the invention is set forth below. Additionaldetails of the summarized embodiments of the invention and/or additionalembodiments of the invention may be found in the Detailed Description ofthe Invention below.

BRIEF SUMMARY OF THE INVENTION

In some embodiments, a package assembly comprises a plurality ofcontainers wrapped in a heat-shrink wrapping. The heat-shrink wrappingdefines a plurality of perforations disposed through the heat-shrinkwrapping. The plurality of perforations are arranged in first and secondpathways and the pathways define a tear strip therebetween.

In some embodiments, the first and second pathways are parallel to oneanother along at least portions thereof.

In some embodiments, the wrapping further defines at least one holetherethrough, the hole being larger than the perforations.

In some embodiments, the pathways intersect at least one hole.

In some embodiments, the tear strip is in the shape of an hour-glass.

In some embodiments, the pathways are parallel to a plane defined by thebottom of the containers.

In some embodiments, the tear strip is removable from the packageassembly.

In some embodiments, the heat-shrink wrapping has a plurality of chadsattached thereto.

In some embodiments, a method of making a package assembly comprisesproviding a plurality of containers and providing a heat-shrinkwrapping. The method further comprises perforating the heat-shrinkwrapping in first and second pathways and wrapping the plurality ofcontainers with the heat-shrink wrapping. The method further comprisesapplying heat to the heat-shrink wrapping and shrinking the heat-shrinkwrapping around the plurality of containers. Additionally, the first andsecond pathways define a tear strip therebetween.

In some embodiments, the method further comprises the step of coolingthe package assembly.

In some embodiments, the step of perforating the heat-shrink wrappingcomprises producing a chad which remains connected to the heat-shrinkwrapping.

In some embodiments, the method further comprises the step of providinga heat-shrink wrapping dispenser.

In some embodiments, a packaging apparatus comprises a heat-shrinkwrapping dispenser, a perforating assembly, and a heat source. Theperforating assembly comprises a die member and a cutting member. Thecutting member is configured to work in conjunction with the die member.The cutting member comprises a die-facing perimeter, the die-facingperimeter having a cutting portion and a non-cutting portion. Thecutting portion extends around only a portion of the die-facingperimeter.

In some embodiments, the cutting member further comprises a bevelextending away from the die-facing perimeter.

In some embodiments, the cutting member further comprises a plurality ofcutting teeth disposed along a portion of its die-facing perimeter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an embodiment of a package assembly.

FIGS. 2-4 show perspective views of the embodiment of the packageassembly of FIG. 1 in various states.

FIGS. 5-12 show perspective views of embodiments of a package assemblyin various arrangements.

FIG. 13 shows an embodiment of a die plate 122.

FIG. 14 shows a perspective view of an embodiment of a package assembly.

FIG. 15 shows a perspective view of an embodiment of a packagingapparatus.

FIG. 16 shows a perspective view of an embodiment of a perforatingassembly.

FIG. 17 shows a perspective view of an embodiment of a cutting member.

FIG. 18 shows a method of making a package assembly.

DETAILED DESCRIPTION OF THE INVENTION

In order to reduce, or overcome, the problems associated withtraditional packaging methods, apparatus, and assemblies, a new packageassembly, method of producing the package assembly, and packagingapparatus are herein disclosed. Each is described, in turn, in thefollowing description.

Package Assembly

With regard to FIG. 1, a package assembly 10 is shown. The packageassembly includes a plurality of containers 12 and a film or heat-shrinkwrapping 14. The containers 12 can be of any desirable shape orconfiguration, for example cylindrical, conical, frusto-conical,spherical, cuboid, pyramidal, and combinations thereof. Additionalexamples of suitable packaging configurations can be found in U.S. Pat.Nos. 7,604,114 to Gessler, 7,392,905 to Andersen, 7,370,761 to Andersen,6,588,594 to Andersen, 5,887,717 to Anderson, and 7,467,504 to Mate, thecontents of each of which are herein incorporated by reference in theirentirety.

In addition to the foregoing, the heat-shrink wrapping 14 hastherethrough a plurality of perforations 16. In some embodiments, theperforations are arranged in one or more pathways 18. As shown in FIG.1, for example, the pathways 18 include a first pathway 18 a and asecond pathway 18 b. Between the first and second pathways 18 a, 18 b isa tear strip 20. The tear strip 20 facilitates easy opening and removalof the heat-shrink wrapping 14. Further, in some embodiments, thepackage assembly 10 includes a base pad 22, on which the containers 12reside. The base pad 22 provides additional support for the containers12 during the packaging assembly and transport.

Turning to FIG. 2, the package assembly 10 shows the tear strip 20 as itis initially pulled away from the remaining heat-shrink wrapping 14. Insome embodiments, the tear strip 20 will originate at a hole 24 (alsoreferred to as a “bulls-eye”, which is a byproduct of known packagingtechniques), for example at an end of the heat-shrink wrapping 14. Itwill be appreciated that, at least in some embodiments, the size of thehole 24 is much larger than the size of a perforation 16.

In FIG. 3, the tear strip 20 is further pulled away from the remainingheat-shrink wrapping 14. As illustrated, the tear strip 20 peels awayfrom the remaining -shrink wrapping 14 along the pathways 18 formed bythe perforations 16.

With regard to FIG. 4, the tear strip 20 is almost fully removed fromthe remaining heat-shrink wrapping 14. In some embodiments, the tearstrip 20 is entirely removable from the package assembly 10, for examplevia perforations extending from hole 24 on one end of the packageassembly 10 to a similar hole 24 on another end, or side, of the packageassembly 10. In some embodiments, however, the tear strip 20 is peeledaway from the remaining heat-shrink wrapping 14 but it is not entirelyremovable. In this way, the orientation of the perforations 16 does notpermit complete removal of the tear strip 20.

With regard to FIG. 5, in some embodiments, the perforations 16 arespaced at least a distance Y away from the hole 24. This minimum spacingensures that a tear does not unintentionally form between hole 24 andthe first perforation 16 a. It will be appreciated that the minimumspacing is a function of the material used for the heat-shrink wrapping14, the heat used to shrink the heat-shrink wrapping 14, orientation ofcontainers 12, and size and shape of the package assembly 10. Indeed,the spacing between the hole 24 and the first perforation 16 a may vary,for example, such that the Y <spacing <X, where X is the maximumpermissible spacing to facilitate tearing of the tear strip 20. Forinstances in which the spacing is greater than X, it becomes toodifficult to start a tear along the tear strip 20.

With regard to FIG. 6, in some embodiments, the pathways 18 are orientedsuch that the tear strip 20 is wider at its ends than middle. In FIG. 6,for example, the tear strip 20 has an hour glass configuration. Such aconfiguration can be desirable, for example, in order to provide easyaccess to the containers 12.

With regard to FIGS. 7 and 8, in some embodiments, the pathways 18 areoriented on one or more sides of the package assembly 10. In FIG. 7, forexample, pathways 18 are disposed on all sides of the package assembly10. In FIG. 8, for example, pathways 18 are disposed on only some of thesides of the package assembly 10. In the embodiments shown in FIGS. 7and 8, the pathways 18 are parallel to one another and parallel to aplane defined by the bottom of the containers 12. Other configurationsare also permissible.

With regard to FIG. 9, the pathways 18 can also be oriented in atransverse direction. In this way, hole 24, which remains after of theshrink process, is located on a side not associated with the tear strip20. Instead, an opening 26 is used at an end 28 of the tear strip 20 tofacilitate removal of the tear strip 20, as desired.

Turning to FIG. 10, in some embodiments, a tear strip 20 is disposed onboth the top 30 and bottom 32 of the package assembly 10. The tearstrips 20 can be symmetric or asymmetric. Further, the orientationand/or configuration of the pathways 18 along the top 30 can be the sameor different than the pathways 18 along the bottom 32.

With regard to FIG. 11, in some embodiments, the pathways 18 extendalong only a portion of the top 30 (or any other surface) of the packageassembly 10. In this way, the tear strip 20 may not be entirelyremovable from the package assembly 10. By maintaining the connectionbetween the tear strip 20 and package assembly 10, it will beappreciated that the user will not have to discard two or more separatewrapper components. Instead, the wrapper will remain in a single piece,with the contents of the package assembly 10 accessible.

With regard to FIG. 12, in some embodiments, the pathways 18 aredifferent from one another such that the first pathway 18 a is shorterthan the second pathway 18b.

With regard to FIG. 14, in some embodiments, the package assembly 10comprises 12 containers. Although shown with 12 containers, it will beappreciated that any suitable number of containers 12 can be used, forexample 4, 6, 8, 9, 10, 12, 20, 25, 100. Further, the containers 12 canbe stacked in multiple rows. Additionally, the package assembly 10 canhave any suitable number of pathways 18 and any suitable number of tearstrips 20.

In at least one embodiment, the heat-shrink wrapping 14 is provided withonly a single pathway 18 of perforations 16. By applying force alongthis single pathway 18 (such as with a user's finger, etc.) theheat-shrink wrapping 14 can be split or otherwise opened along thepathway 18.

Packaging Apparatus

Turning to FIG. 15, an embodiment of the packaging apparatus 100 isshown therein. In some embodiments, the packaging apparatus 100comprises a heat-shrink wrapping dispenser 102. The packaging apparatus100 further comprises a perforating assembly 106, a heating source 108,a first conveyor 110 and a second conveyor 112.

In some embodiments, the heat-shrink wrapping dispenser 102 comprises atleast one roll of heat-shrink wrapping 14 which feeds out of theheat-shrink wrapping dispenser 102.

As shown in greater detail in FIG. 16, the perforating assembly 106comprises a die member 114 and a cutting member 116. The die member 114works in conjunction with the cutting member 116 to make theperforations 16 in the heat-shrink wrapping 14. As will be appreciated,the cutting member(s) 116 move in and out of the die member(s) 114 toperforate the heat-shrink wrapping 14. Further, the die member 114 has asupport 115 which is disposed on a backside of the heat-shrink wrapping14 to provide support as the perforations are cut 16.

With regard to FIG. 17, a cutting member 116 or punch is shown ingreater detail. In some embodiments, the cutting member 116 has aplurality of cutting teeth 118 along a portion of its die-facingperimeter 113. In some embodiments, the cutting teeth 118 do not extendaround the entirety of the die-facing perimeter 113, however. Instead,the cutting member 116 has a cutting portion 124 and a non-cuttingportion 126 to facilitate creation of non-severed or hanging chads 120.In some embodiments, the non-cutting portion 126 comprises a bevel 117that extends away from the die-facing perimeter 113. In this way, thecutting member 116 perforates the heat-shrink wrapping 14 withoutsevering the chad 120 (FIG. 15) from the heat-shrink wrapping 14. Thechad 120 thereby remains attached to the heat-shrink wrapping 14.Maintaining attachment of the chad 120 to the heat-shrink wrapping 14 isbeneficial, in some embodiments, in order to reduce or eliminate theproduction of waste material, which can clutter the assembly process.Consequently, there are no chads 120 to pick up or dispose of. This, inturn, reduces cost and machine down-time.

In some embodiments, the cutting member 116 produces perforations 16having c-shape or v-shape perimeters, such that the open part of the “c”or “v” remains attached to the heat-shrink wrapping 14.

With further regard to the cutting member 116, the skilled artisan willappreciate that it can take on any desirable cross-section, for examplecircular, triangular, square, rectangular, elliptical, rhomboid, or anyother suitable shape or polygon. Examples of some suitable crosssections are shown via die plate 122 in FIG. 13. The die plate 122 canbe used in conjunction with the die member 114 such that the shape ofthe perforations 16 can be changed, as desired. Returning to FIG. 15, insome embodiments, the perforating assembly 106 perforates theheat-shrink wrapping 14 while the heat-shrink wrapping 14 is staticallypositioned. The heat-shrink wrapping 14 is therefore indexed orotherwise stopped to permit the cutting member 116 or punch to beactuated, thereby penetrating the heat-shrink wrapping 14.

In some embodiments, the perforating assembly 106 is adjustable topermit an operator to easily adjust the pitch of the perforations 16 andthe depth of cutting member 116 travel, for example to regulate theamount of material holding the chad 120 to the heat-shrink wrapping 14.In some embodiments, an actuator is used to relocate one or more groupsof cutting members 116 or punches and die members 114 to adjust thepattern of the perforations. Further, it will be appreciated that theactuator(s) and die members 114 can be employed in any configuration oralong any axis in order to adjust the pattern and orientation of theperforations 16. And, the packaging apparatus 100 can be used, forexample, in conjunction with the “Packaging System for Split PackageAssembly,” disclosed in U.S. Pat. No. 7,467,504, the contents of whichare herein incorporated by reference.

Method of Making Package Assembly

As illustrated via FIG. 18, a method of making the package assembly 200is described. In some embodiments, the method includes the steps ofproviding the containers 202. In some embodiments, the packagingapparatus 100 (FIG. 15) can be added to an existing assembly line, forexample, where the containers were previously assembled onto a base pad22 or the like. The method of making the package assembly 200 furthercomprises the steps of providing a heat-shrink wrapping 204 andperforating the heat-shrink wrapping 206. After the heat-shrink wrapping14 has been perforated, it is applied to the containers via step 208.Thereafter, heat is applied to the heat-shrink wrapping 14 at step 210to shrink the heat-shrink wrapping 14.

As will be appreciated, upon application of heat to the heat-shrinkwrapping 14, the size of the perforations 16 is reduced. Further, thechads 120 (FIG. 15) shrink in size and do not appear unsightly, uponcompletion of the package assembly, or interfere with any additionalpackaging processes.

In order to facilitate homogeneity, reduce viscosity, or to destroypathogens, mixing machines commonly heat packaged product totemperatures ranging from fifty to ninety degrees Celsius. In theproduction of perishable goods, and more specifically, perishable goodswhich can be spoiled by transient periods at moderate temperatures,rapid cooling of the final package becomes of critical importance.Moreover, minimizing package cooling time allows the producer to cyclethrough product more quickly, reducing work-in-process and spacerequirements, thus increasing profitability.

It has been determined that strategically located apertures, when usedin conjunction with adequate airflow, can reduce cooling cycles by morethan twenty-five percent. Cooling speed, or time rate of thermaldissipation, is increased because the apertures simultaneously increasethe exposed heat-dissipating surface area, and reduce the airtemperature in the vicinity of the heat-dissipating surfaces. Moreover,by locating the apertures where tension is low in the wrapping, packageintegrity can be preserved.

Consequently, the embodiments disclosed in the immediate disclosure haveadvantages over previously known package assemblies, methods, andpackaging apparatus.

Additionally, it will be appreciated that embodiments havingperforations on opposite sides of the packaging apparatus 10 (e.g.,FIGS. 7 and 10), more than one perforating assembly 106 can be used.

The above disclosure is intended to be illustrative and not exhaustive.This description will suggest many variations and alternatives to one ofordinary skill in this field of art. All these alternatives andvariations are intended to be included within the scope of the claimswhere the term “comprising” means “including, but not limited to.”Thosefamiliar with the art may recognize other equivalents to the specificembodiments described herein which equivalents are also intended to beencompassed by the claims.

Further, the particular features presented in the dependent claims canbe combined with each other in other manners within the scope of theinvention such that the invention should be recognized as alsospecifically directed to other embodiments having any other possiblecombination of the features of the dependent claims. For instance, forpurposes of claim publication, any dependent claim which follows shouldbe taken as alternatively written in a multiple dependent form from allprior claims which possess all antecedents referenced in such dependentclaim if such multiple dependent format is an accepted format within thejurisdiction (e.g. each claim depending directly from claim 1 should bealternatively taken as depending from all previous claims). Injurisdictions where multiple dependent claim formats are restricted, thefollowing dependent claims should each be also taken as alternativelywritten in each singly dependent claim format which creates a dependencyfrom a prior antecedent-possessing claim other than the specific claimlisted in such dependent claim below.

This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

What is claimed is:
 1. A package assembly comprising: a plurality ofcontainers wrapped in a heat-shrink wrapping, the heat-shrink wrappingdefining a plurality of perforations disposed therethrough, theplurality of perforations arranged in first and second pathways, thepathways defining a tear strip therebetween.
 2. The package assembly ofclaim 1, wherein the first and second pathways are parallel to oneanother along at least portions thereof
 3. The package assembly of claim1, wherein the heat-shrink wrapping further defines at least one holetherethrough, the hole being larger than the perforations.
 4. Thepackage assembly of claim 3, wherein the pathways intersect the at leastone hole.
 5. The package assembly of claim 1, wherein the tear strip isin the shape of an hour-glass.
 6. The package assembly of claim 1,wherein the pathways are parallel to a plane defined by the bottom ofthe containers.
 7. The package assembly of claim 1, wherein the tearstrip is removable from the package assembly.
 8. The package assembly ofclaim 1, wherein the heat-shrink wrapping has a plurality of chadsattached thereto.
 9. A method of making a package assembly comprising:providing a plurality of containers; providing a heat-shrink wrapping;perforating the heat-shrink wrapping in first and second pathways;wrapping the plurality of containers with the heat-shrink wrapping;applying heat to the heat-shrink wrapping; and shrinking the heat-shrinkwrapping around the plurality of containers, wherein the first andsecond pathways define a tear strip therebetween.
 10. The method ofclaim 9, further comprising cooling the package assembly.
 11. The methodof claim 9, wherein the step of perforating the heat-shrink wrappingcomprises producing a chad which remains connected to the heat-shrinkwrapping.
 12. The method of claim 9, further comprising providing aheat-shrink wrapping dispenser.